Process for production of polymer dispersions containing an acetoacetate moiety

ABSTRACT

A method of making a composition comprising reacting, in a reactor, a non-halogenated acetoacetate group containing monomer, at least one additional monomer, and a base, wherein at least a portion of the base is fed to the reactor during reaction. Also, a composition comprising an aqueous polymer dispersion that is a product of a method comprising reacting a non-halogenated acetoacetate moiety containing monomer, at least one additional monomer, and a base, wherein the base is fed to the reaction during reaction, wherein the composition has a lower viscosity than a second composition, wherein the second composition is prepared from the same materials as the composition, and the second composition is made by a method wherein the base is added to the second composition after a reaction to form the second composition.

BACKGROUND OF THE INVENTION

Acetoacetate moieties in polymers have been used to make crosslinkablepolymers. These polymers are useful in coatings. Generally, the polymersare prepared from monomer mixtures that contain a monomer with anacetoacetate moiety. After the polymer is formed, the polymer isneutralized with a base.

These polymers are often associated with a high viscosity. Higherviscosities increase the difficulty of manufacture and transportation ofthe polymers. Lower viscosities are generally desirable for reasons ofheat transfer and energy consumption during manufacturing. Also, lowerviscosities allow for easier pumping and handling. Decreased viscositiesalso allow for increased solids contents, which is desirable intransportation in that less water has to be shipped.

It would be desirable to make an acetoacetate moiety containing polymerwith a lower viscosity.

SUMMARY OF THE INVENTION

The present invention relates to a method of making a compositioncomprising reacting, in a reactor, a non-halogenated acetoacetate groupcontaining monomer, at least one additional monomer, and a base, whereinat least a portion of the base is fed to the reactor during reaction.

The present invention also relates to a composition comprising anaqueous polymer dispersion that is a product of a method comprisingreacting a non-halogenated acetoacetate moiety containing monomer, atleast one additional monomer, and a base, wherein the base is fed to thereaction during reaction, wherein the composition has a lower viscositythan a second composition, wherein the second composition is preparedfrom the same materials as the composition, and the second compositionis made by a method wherein the base is added to the second compositionafter a reaction to form the second composition, and wherein the atleast one additional monomer is not butadiene.

DETAILED DESCRIPTION

As used throughout, ranges are used as a shorthand for describing eachand every value that is within the range. Any value within the range canbe selected as the terminus of the range.

A composition is prepared by reacting a non-halogenated acetoacetatemoiety containing monomer, at least one additional monomer, and a base,wherein the base is fed to the reaction. The composition of the presentinvention is prepared as an aqueous polymer dispersion. The compositionhas a lower viscosity than a second composition prepared from the samematerials as the composition, wherein the second composition is made bya method wherein the base is added to the second composition after areaction to form the second composition. By changing the point at whicha base is added, a different composition is formed. The difference canbe seen in the viscosity of the compositions. The composition of thepresent invention will have a lower viscosity than the secondcomposition. Also, when the composition is included in a coatingcomposition and tested for scrub resistance according to ASTM D-2486,the composition will have a higher scrub resistance as compared to thesecond composition.

The base is fed to the reaction while the monomers are reacting. Aportion of the total base can be provided in the reactor prior to thestart of reaction. Preferably, less than 50% of the total amount of baseis present in the reactor at the start of the reaction. More preferably,none of the base is present in the reactor at the start of reaction. Thebase can be present with the monomers as the monomers are fed to thereactor, or the base can be fed from a separate feed, or a combinationof both. In a preferred embodiment, the base is fed with the monomers.

The bases that are suitable for use in the present invention includethose substances by the following three definitions: (1) a compound thatdissociates on solution in water to produce one or more hydroxyl ions;(2) any compound which can accept a proton by a more general definitionaccording to the Brönsted concept and (3) anything which has anun-shared pair of electrons according to a still more general concept ofG. N. Lewis. Within the scope of the three definitions, the class ofcompounds that are commonly used in preparing buffers are also includedand can be used. A buffer is a solution of a compound that has thecapability of minimizing changes in proton (hydrogen ion) concentration.

General examples of the base include, but are not limited to, alkalimetal hydroxides, alkaline earth metal hydroxides, hydroxides ofelements from Groups 7 through 13 in the periodic table (IUPACNomenclature), ammonia, ammonium hydroxide, amines including primaryamines, secondary amines, and tertiary amines such as, but not limitedto, alkylamines, arylamines, and heterocyclic amines.

Preferred bases include, but not limited to, lithium hydroxide, sodiumhydroxide, potassium hydroxide, magnesium hydroxide, calcium hydroxide,barium hydroxide, ammonia, ammonium hydroxide, alkylamines such asmethylamines, ethylamines, propylamines, dimethylamines, diethylamines,trimethylamines, and triethylamines, 2-amino-2-methyl-1-propanol,triethanolamine, compounds with buffering capabilities such ascarbonates and bicarbonates of alkali metals (preferably lithium,sodium, or potassium), ammonium carbonate, ammonium bicarbonate, mono-and dibasic phosphates of alkali metals, ammonium mono- and dibasicphosphates, tetroxalates and tartrates of alkali metals, ammoniumtetroxalate, ammonium tartrate, phthalates of alkali metals, andammonium phthalate.

Depending upon the types and amounts of monomers, the amount of base isselected so that undesired results are minimized or avoided. Forexample, if esters of (meth)acrylic acid are used, too much base canlead to excessive hydrolysis of the monomers. Also, too much base candrive monomers with acid groups to the aqueous phase and reduce theamount of the acid groups attached covalently to the particles, whichcan decrease the stability of the polymer particles.

In a preferred embodiment, the base is added during the reacting step inan amount to provide a pH that is at least 0.2 units higher than wouldbe obtained if the base were not used. In another preferred embodiment,the base is added during the reacting step in an amount such that the pHis not higher than 7. In another preferred embodiment, the base is addedduring the reacting step in an amount to provide a pH that is at least0.2 units higher than would be obtained if the base were not used, andthe base is added during the reacting step in an amount such that the pHis not higher than 7. In another preferred embodiment, the base is usedin an amount of from about 0.01 to about 2 weight % based on a totalweight of the polymer.

A non-halogenated acetoacetate moiety has the following generalstructure: —R₁—C(O)—CH₂—X, where R₁ is a divalent organic radical atleast three atoms in length, X is organoacyl [—C(O)—R₂] or cyano [—CN],wherein R₂ is a methyl group [—CH₃] or a monovalent organic radical, andthere is no halogen atom on the carbon atom between the two carbonylcarbon atoms. Examples of acetoacetate moiety containing monomers can befound in U.S. Pat. No. 3,459,790, which is incorporated herein byreference. Preferred ethylenically-unsaturated acetoacetate moietycontaining monomers include, but are not limited to, 2-acetoacetoxyethyl(meth)acrylate, 3-acetoacetoxypropyl (meth)acrylate, 4-acetoacetoxybutyl(meth)acrylate, 2-cyanoacetoxyethyl (meth)acrylate, 3-cyanoacetoxypropyl(meth)acrylate, 4-cyanoacetoxybutyl (meth)acrylate,N-(2-acetoacetoxyethyl) (meth)acrylamide, allyl acetoacetate,2,3-di(acetoacetoxy)propyl (meth)acrylate, vinyl acetoacetate, andcombinations thereof.

In a preferred embodiment, the non-halogenated acetoacetate moietycontaining monomer is present in an amount from about 0.1 to about 25weight % based on a total weight of the polymer.

The at least one additional monomer makes up that balance of themonomers. In a preferred embodiment, the at least one additional monomeris present in an amount from about 70 to about 99.9 weight % based on atotal weight of the polymer.

The at least one additional monomer suitable for the reaction productsof the present invention include all monomers that can be reacted withan acetoacetate moiety containing monomer to form an aqueous dispersionpolymer. Such monomers can be any ethylenically unsaturated monomer thatcan be polymerized by a free-radical mechanism. Examples of thesemonomers can be found in U.S. Patent Application Publication No.2003/0195297, which is incorporated herein by reference. Suitableexamples of the at least one additional monomer include, but are notlimited to, (meth)acrylates, hydroxyl containing (meth)acrylates, vinylaromatics, vinyl halides, vinylidene halides, esters of vinyl alcoholand C₁-C₁₈ monocarboxylic acids, esters of allyl alcohol and C₁-C₁₈monocarboxylic acids, ethylenically unsaturated monomers containing atleast one carboxylic acid group, salts of ethylenically unsaturatedmonomers containing at least one carboxylic acid group, anhydrides ofethylenically unsaturated dicarboxylic acids, nitriles of ethylenicallyunsaturated carboxylic acids, ethylenically unsaturated monomerscontaining at least one sulfonic acid group, salts of ethylenicallyunsaturated monomers containing at least one sulfonic acid group,ethylenically unsaturated monomers containing at least one amide group,dienes, alkyds, nitrogen-containing adhesion monomers, glycidyl estersof ethylenically unsaturated monomers, vinyl esters of the formulaCH₂═CH—O—(CO)—C—(R₁₀₀)₃ wherein R₁₀₀ is an alkyl (sold under the tradename VEOVA™ by Shell), alkylaminoalkyl group-containing (meth)acrylicmonomers, alkyl esters of (meth)acrylic acid containing an ether bond inthe alkyl, urethane esters of (meth)acrylic acid, urea esters of(meth)acrylic acid, vinyl monomers, isocyanate esters of (meth)acrylicacid, carbonyl containing monomers, monomers containing hydrolyzableSi-organic bonds, vinyl esters of neo acids (such as those sold underthe trade name EXXAR™ NEO 10 and NEO 12 from Exxon), enamines, alkylcrotonates, phosphate (meth)acrylates, and (meth)acryloxy benzophenones.

The (meth)acrylates are reaction products of ethylenically unsaturatedcarboxylic acids and C₁-C₁₈ alcohols. Examples of (meth)acrylatesinclude, but are not limited to, methyl (meth)acrylate, ethyl(meth)acrylate, propyl (meth)acrylate, n-butyl (meth)acrylate, isobutyl(meth)acrylate, t-butyl (meth)acrylate, pentyl (meth)acrylate, hexyl(meth)acrylate, cyclohexyl (meth)acrylate, benzyl (meth)acrylate,2-ethylhexyl (meth)acrylate, heptyl (meth)acrylate, n-octyl(meth)acrylate, nonyl (meth)acrylate, decyl (meth)acrylate, undecyl(meth)acrylate, dodecyl (meth)acrylate, tridecyl (meth)acrylate, lauryl(meth)acrylate, stearyl (meth)acrylate, isobornyl (meth)acrylate,norbornyl (meth)acrylate, 4-tertbutylcyclohexyl (meth)acrylate,3,3,5-trimethylcyclohexyl (meth)acrylate, dimethyl maleate, n-butylmaleate, alkylene glycol di(meth)acrylates, ethylene glycoldi(meth)acrylate, 1,3-butylene glycol di(meth)acrylate, 1,4-butyleneglycol di(meth)acrylate, propylene glycol (meth)acrylate, 1,6-hexanedioldi(meth)acrylate, dipropylene glycol di(meth)acrylate, tripropyleneglycol di(meth)acrylate, trimethylolpropane tri(meth)acrylate,cyclopentadienyl (meth)acrylate, carbodiimide (meth)acrylate,t-butylaminoethyl (meth)acrylate, 2-t-butylaminoethyl (meth)acrylate,and N,N-dimethylaminoethyl (meth)acrylate. The pendant group may containone or more hetero atoms, aromatic groups, or ethylenic unsaturation.

Examples of hydroxyl containing (meth)acrylates include, but are notlimited to, 2-hydroxyethyl (meth)acrylate, hydroxypropyl(meth)acrylates, and hydroxybutyl (meth)acrylates.

Examples of ethylenically unsaturated monomers containing at least onecarboxylic acid group include, but are not limited to, (meth)acrylicacid, maleic acid, fumaric acid, itaconic acid, ethacrylic acid,crotonic acid, citraconic acid, cinnamic acid, phthalic acid,isophthalic acid, terephthalic acid, tetrahydrophthalic acid,hexahydrophthalic acid, tetrabromophthalic acid, trimellitic acid,pyromellitic acid, 1,4,5,6,7,7-hexachloro-5-norbornene-2,3-dicarboxylicacid, succinic acid, 2,6-naphthalenedicarboxylic acid, glutaric acid,sebacic acid, azelaic acid, 1,4-cyclohexanedicarboxylic acid, and1,3-cyclohexanedicarbocylic acid.

Examples of anhydrides of ethylenically unsaturated dicarboxylic acidsinclude, but are not limited to, maleic anhydride, succinic anhydride,phthalic anhydride, tetrahydrophthalic anhydride, hexahydrophthalicanhydride, tetrabromophthalic anhydride, trimellitic anhydride,pyromellitic anhydride, and1,4,5,6,7,7-hexachloro-5-norbornene-2,3-dicarboxylic anhydride.

Examples of esters of ethylenically unsaturated monomers containing atleast one carboxylic acid group include, but are not limited to, methylhydrogen fumarate, benzyl hydrogen maleate, butyl hydrogen maleate,octyl hydrogen itaconate, dodecyl hydrogen citraconate, butyl fumarate,octyl fumarate, octyl maleate, dibutyl maleate, and dioctyl maleate.

Examples of esters of vinyl alcohol and C₂-C₁₈ monocarboxylic acidsinclude, but are not limited to, vinyl acetate, vinyl acetoacetate,vinyl propionate, vinyl n-butyrate, vinyl heptanoate, vinyl perlogonate,vinyl 3,6-dioxaheptanoate, vinyl 3,6,9-trioxanundecanote, vinyl laurate,and vinyl stearate. Examples of esters of allyl alcohol and C₁-C₁₈monocarboxylic acids include, but are not limited to, allyl acetate,allyl propionate, allyl (meth)acrylate, allyl n-butyrate, allyl laurate,allyl stearate, diallyl maleate, and diallyl fumarate.

Examples of suitable nitriles of ethylenically unsaturated carboxylicacids include, but are not limited to, acrylonitrile andmethacrylonitrile. Examples of vinyl aromatics include, but are notlimited to, styrene, α-methyl styrene, o-chlorostyrene, chloromethylstyrene, α-phenyl styrene, styrene sulfonic acid, salts of styrenesulfonic acid, para-acetoxystyrene, divinylbenzene, diallyl phthalate,vinyl toluene, and vinyl naphthalene. Examples of dienes include, butare not limited to, butadiene, isoprene, and chloroprene.

Examples of unsaturated monomers containing at least one sulfonic acidgroup include, but are not limited to, vinyl sulfonic acid, arylsulfonicacid, sulfopropyl acrylate, (Meth)acryloyloxynaphthalenesulfonic acid,2-acrylamido-2-methylpropanesulfonic acid, andacryloyloxybenzenesulfonic acid.

Examples of unsaturated monomers containing at least one amide groupinclude, but are not limited to, (meth)acrylamide, dimethyl(meth)acrylamide, N-alkyl (meth)acrylamide, N-butylacrylamide,tetramethylbutylacrylamide, N-alkylol (meth)acrylamide, N-methylol(meth)acrylamide, N-octyl acrylamide, methylene bis acrylamide,diacetoneacrylamide, ethyl imidazolidon (meth)acrylate, andN,N-dimethylaminopropylmethacrylamide.

As used throughout this specification and claims, nitrogen-containingadhesion monomers are free-radically polymerizable monomers that have atleast one of an amino group, a ureido group, a urea group, a thioureagroup, and a N-heterocyclic group. Examples of nitrogen-containingadhesion monomers include, but are not limited to, ureido(meth)acrylates, (meth)acrylates with at least one of urea and thioureain the side chains, acrylic allophanes, aminoethyl acrylate andmethacrylate, dimethylaminoethyl acrylate and methacrylate,diethylaminoethyl acrylate and methacrylate, dimethylaminopropylacrylate and methacrylate, 3-dimethylamino-2,2-dimethylpropyl acrylateand methacrylate, 2-N-morpholinoethyl acrylate and methacrylate,2-N-piperidinoethyl acrylate and methacrylate,N-(3-dimethylaminopropyl)acrylamide and -methacrylamide,N-dimethylaminoethylacrylamide and -methacrylamide,N-diethylaminoethylacrylamide and -methacrylamide,N-(4-morpholinomethyl)acrylamide and -methacrylamide, vinylimidazole andalso monoethylenically unsaturated derivatives of ethyleneurea, such asN-(2-(meth)acryloyloxyethyl)ethyleneurea,N-(β-acrylamidoethyl)ethyleneurea,N-2-(allylcarbamato)aminoethylimidazolidinone, N-vinylethyleneurea,N-(3-allyloxy-2-hydroxypropyl)aminoethylethyleneurea,N-vinyloxyethyleneurea, N-methacryloyloxyacetoxyethylethyleneurea,N-(acrylamidoethylene)ethyleneurea,N-(methacrylamidoethylene)-ethyleneurea,1-(2-methacryloyloxyethyl)imidazolin-2-one, andN-(methacrylamidoethyl)ethyleneurea.

Examples of carbonyl-containing monomers include, but are not limitedto, acrolein and methacrolein.

Examples of the monomers containing hydrolyzable Si-organic bondsinclude, but are not limited to, vinyl silanes,methacryloyloxypropyltrimethoxysilane,methacryloyloxypropyltriethoxysilane,methacryloyloxypropyltripropxysilane,methacryloyloxypropyltriisopropxysilane, vinyltrimethoxysilane, vinyltris (2-methoxyethoxy silane), and vinyl triisopropoxysilane.

Examples of the phosphate (meth)acrylates include, but are not limitedto, sodium phosphate (meth)acrylate, alkylester phosphate(meth)acrylate, and ethoxylated alkylester phosphate (meth)acrylate.

Other vinyl monomers include, but are not limited to, 1,4-butanediolbisacrylate, vinyl acetoacetamide, vinyl 1,3-diketone, vinylpyrrolidone, vinyl pyridine, vinyl pyrazine, vinyl piperadiene, vinylpiperidone, vinyl pyrimidine, vinyl pyrrole, vinyl imidazole, vinylcaprolactam, vinyl oxazole, vinyl thiazole, vinyl morpholine, triallylcyanurate, glycidyl (meth)acrylate, 3-isopropenyl-α-α-dimethylbenzylisocyanate, ethylene, and propylene.

In a preferred embodiment, the majority of the at least one additionalmonomer is not a functional monomer. A functional monomer is a monomerthat has a functional group in addition to a carbon-carbon double bondor has at least two sites of ethylenic unsaturation. Functional groupsinclude, but are not limited to, acids, hydroxyls, amides, nitrogencontaining groups (such as those in the nitrogen-containing adhesionmonomers listed above), silanes. Preferably, the functional monomers inthis embodiment are present in an amount from about 0.05 to about 5% byweight based on a total weight of the polymer.

Examples of functional monomers are given above. Preferred functionalmonomers include, but are not limited to, mono-ethylenically unsaturatedacids and diacids, such as acrylic acid, methacrylic acid, itaconicacid, and maleic acid; nitrogen-containing monomers such as acrylamide,methacrylamide, ureido (meth)acrylate, and ureido (meth)acrylamide; AMPS(acrylamidomethypropylsufonic acid or its salts); silane monomers suchas methacryloxypropyl trimethoxysilane, methacryloxypropyltriethoxysilane, methacryloxypropyl tripropoxysilane,vinyltrimethoxysilane, and vinyltriethoxysilane; crosslinkers with twoor more sites of ethylenic unsaturation, such as ethylene glycoldimethacrylate, diethylene glycol dimethacrylate, trimethylolpropanetrimethacrylate, 1,3-butyleneglycol dimethacrylate, and1,4-butyleneglycol dimethacrylate; ethoxylated vinyl or (meth)acrylicmonomers such as PLURIOL® A010R (commercially available from BASF AG),

and BOSOMER™ MPEG 350 MA (commercially available from Laporte),

In the above monomers, references are made to various acids or salts ofthese acids. When listed, the reference to the acid also includes areference to its salts. The salts of theses acids include alkali metalsalts, alkaline earth metal salts, and ammonium salts.

The polymers of the present invention can be made in a seedlesssemi-batch polymerization, an in-situ seeded semi-batch polymerization,a seeded semi-batch polymerization, or a continuous polymerization. Inthese polymerizations, the polymers of the present invention can be madeas a single stage polymer, a gradient or power-feed polymer, or they canbe made as a multiple stage polymer.

The reaction to form the polymers of the present invention can be anemulsion polymerization reaction in which the monomers are emulsified inwater with a surface active agent or stabilized by a protective colloidand reacted using emulsion polymerization techniques known in the art.The resulting product of the emulsion polymerization is an aqueouspolymer dispersion, also known as a latex.

The reaction can be started with any initiator. In the reaction,additional materials that are used in emulsion polymerizations can beincluded. Examples of additional materials include, but are not limitedto, electrolytes, chelating agents, dispersing agents, chain transferagents, and additional seed polymer particles. At the end of thereaction, typically a redox system, which includes an oxidizing agentand a reducing agent, is added to the reaction product to drive thereaction to further completion to reduce the amount of residualmonomers. Alternatively, any system that reduces residual monomercontent can be used. Examples include, but are not limited to, strippingwith steam, vacuum, use of adsorbent materials, and combinationsthereof.

Any temperature that allows the monomers to react to form a polymer canbe used as a reaction temperature. Generally, emulsion polymerizationreactions have a reaction temperature that ranges from about 3° C. toabout 130° C.

Examples of surface active agents (surfactants) that can be used in thepresent invention include anionic, cationic, nonionic, amphotericsurfactants, and mixtures thereof.

Examples of anionic surfactants include, but are not limited to,organosulfates and sulfonates, e.g., sodium and potassium alkyl, aryl,and arylalkyl sulfates and sulfonates, such as sodium 2-ethylhexylsulfate, potassium 2-ethylhexyl sulfate, sodium nonyl sulfate, sodiumlauryl sulfate, potassium methylbenzene sulfonate, sodium dodecylbenzenesulfonate, potassium toluene sulfonate, and sodium xylene sulfonate;higher fatty alcohols, e.g., stearyl, lauryl, etc., which have beenethoxylated and sulfonated; dialkyl esters of alkali metal sulfosuccinicacid salts, such as sodium diamyl sulfosuccinate, sodium dioxtylsulfosuccinate, and sodium dioctyl sulfosuccinate,formaldehyde-naphthalene sulfonic acid condensation products; and alkalimetal salts, partial alkali metal salts, free acids of complex organicphosphate esters, and sodium salt of a fatty alcohol ether sulfate(EMULPHOR™ FAS 30 from BASF AG or DISPONIL™ FES 77 from Cognis, Inc.).

Examples of cationic surfactants include, but are not limited to,alkylamine salts such as laurylamine acetate, quaternary ammonium saltssuch as lauryl trimethyl ammonium chloride and alkyl benzyldimethylammonium chlorides, and polyoxyethylenealkylamines.

Examples of amphoteric surfactants include, but are not limited to,alkylbetaines such as lauryl-betaine.

Examples of nonionic surfactants include, but are not limited to,polyethers, e.g., ethylene oxide and propylene oxide condensates thatinclude straight and branched chain alkyl and alkylaryl polyethyleneglycol and polypropylene glycol ethers and thioethers; alkylphenoxypoly(ethyleneoxy) ethanols having alkyl groups containing from about 7 toabout 18 carbon atoms and having from about 4 to about 240 ethyleneoxyunits, such as heptylphenoxypoly (ethyleneoxy) ethanols,nonylphenoxypoly (ethyleneoxy) ethanols; the polyoxyalkylene derivativesof hexitol including sorbitans, sorbides, mannitans and mannides;partial long-chain fatty acids esters, such as the polyoxyalkylenederivatives of sorbitan monolaurate, sorbitan monopalmitate, sorbitanmonostearate, sorbitan tristearate, sorbitan monooleate and sorbitantrioleate; the condensates of ethylene oxide with a hydrophobic base,the base being formed by condensing propylene oxide with propyleneglycol; sulfur containing condensates, e.g., those prepared bycondensing ethylene oxide with higher alkyl mercaptans, such as nonyl,dodecyl, or tetradecyl mercaptan, or with alkylthiophenols wherein thealkyl group contains from about 6 to about 15 carbon atoms; ethyleneoxide derivatives of long-chain carboxylic acids, such as lauric,myristic, palmitic, or oleic acids or mixtures of acids, such as talloil fatty acids; ethylene oxide derivatives of long-chain alcohols suchas octyl, decyl, lauryl, or cetyl alcohols; and ethylene oxide/propyleneoxide copolymers sold under the tradename PLURONIC™ from BASF AG.Another nonionic surfactant is an organosilanol derivative of tung oil,or linseed oil, or high erucic acid rapeseed oil. These surfactantcompositions particularly feature high surface activity in formingstable emulsions of organic/water of various difficult to emulsifymaterials as compared with conventional emulsifying agents. Thesesilanol-based surfactant compositions are described in U.S. Pat. No.5,807,922.

Another class of surfactants that can be used are those that arecopolymerizable with the monomers described above.

In emulsion polymerization, the amount of surfactants in the emulsionpolymerization reaction range from about 0.01 to about 10 weightpercent, preferably about 0.2 to about 5 weight percent based on thetotal weight of monomers and water.

Initiators that can be used in a reaction to prepare the polymers of thepresent invention can be an oxidizer alone or a redox pair of oxidizingand reducing agents. Oxidizers that can be used alone or in the redoxsystem include, but are not limited to, peroxides such as t-butylhydroperoxide, hydrogen peroxide, pinane hydroperoxide, dibenzoylperoxide, cumol hydroperoxide, persulfates such as peroxodisulfuricacid, salts of peroxodisulfuric acid, azo compounds such asazobisisobutyronitrile, agents that donate oxygen with free radicalformation, alkali metal chlorates, alkali metal perchlorates, transitionmetal oxide compounds, potassium permaganate, manganese dioxide, leadoxide, lead tetraacetate, iodobenzene. Reducing agents that can beincluded in the redox system include, but are not limited to, sodiumformaldehyde sulfoxylate, erythorbic acid, bisulfites, sodiummetabisulfite, sodium bisulfite, adducts of a 3 to 8 carbon ketone withthe bisulfite ion, adducts of a 3 to 8 carbon ketone with sulfurousacid, reducing sugars, ascorbic acid, sulfinic acids,hydroxymethane-sulfinic acid, alkane sulfinic acids, isopropane sulfinicacid. Additional redox systems are described in U.S. Pat. No. 5,994,457,which is incorporated herein by reference.

Additional polymers that can be blended with the polymer compositions ofthe present invention include, but are not limited to, (meth)acrylates,styrenics, styrene-butadienes, polyurethanes, polyethers, polyesters,melamine-formaldehyde polymers, vinyl halides, vinylidene halides,poly(ethyleneimines), and poly(vinyl amines).

Before the addition of post reaction additives to prepare specificdesired compositions, the reaction products (the aqueous polymerdispersions) of the present invention generally have a total solidscontent of from about 30% to about 70% and a pH from about 2 to about 7.The pH of the reaction products can be adjusted to above 7 if requiredusing a pH adjusting agent as described below. The particle size cangenerally range from about 30 nm to about 1000 nm. The particle sizedistribution can be uni- or multi-modal.

The compositions of the present invention may further contain additionaladditives. The additives can be any additive that may be generallyincluded with an emulsion polymerization reaction product or anyadditive that may be used to make a specific composition. Furtheradditives include, but are not limited to, surfactants, wetting agents,protective colloids, fillers, coloring agents, antiseptics, biocides,dispersing agents, thickening agents, thixotropic agents, antifreezingagents, pH adjusting agents, corrosion inhibitors, ultraviolet lightstabilizers, crosslinking promoters, and antioxidants.

Examples of surfactants and wetting agents include, but are not limitedto, the surfactants listed above, sulfosuccinates, fluorinatedsurfactants, and silicone surfactants.

Examples of protective colloids are partially and fully hydrolyzedpolyvinyl alcohol, hydroxyethyl cellulose, hydroxymethyl cellulose,ethylhydroxyethyl cellulose, carboxymethyl cellulose, ethoxylated starchderivatives, polyacrylic acid, alkali metal polyacrylates,polyacrylamide, poly (methyl vinyl ether/maleic anhydride),polyvinylpyrrolidone, water soluble starch, glue, gelatin, water solublealginates, guar, gum arabic, and gum tragacanth. The amount ofprotective colloids used in the composition varies depending upon theintended application and generally ranges from about 0.1 weight percentto about 2 weight percent based on the total weight of the composition.

Examples of fillers include talc, calcium carbonate, diatomaceous earth,mica, kaolin, barium sulfate, magnesium carbonate, fumed silica,vermiculite, graphite, alumina, silica, and rubber powder. Coloringagents such as titanium dioxide and carbon black can also be used as thefillers. The amount of the filler generally ranges from about 5 weightpercent to about 50 weight percent based on the total weight of thecomposition of the present invention.

Various organic pigments and inorganic pigments may be broadly used asthe coloring agents, but non-toxic anticorrosive pigments are preferred.Examples of such pigments are phosphate-type anticorrosive pigments suchas zinc phosphate, calcium phosphate, aluminum phosphate, titaniumphosphate, silicon phosphate, and ortho- and fused phosphates of these;molybdate-type anticorrosive pigments such as zinc molybdate, calciummolybdate, calcium zinc molybdate, potassium zinc molybdate, potassiumzinc phosphomolybdate and potassium calcium phosphomolybdate; andborate-type anticorrosive pigments such as calcium borate, zinc borate,barium borate, barium meta-borate and calcium meta-borate. Also, anycolor pigment, effect pigment, or color and effect pigment may be used.The amount of the coloring agent used may also be properly selectedbased on the end-use application of the compositions of the presentinvention.

Examples of the antiseptics are pyrrole compounds, imidazole compounds,thiazole compounds, pyridine compounds and organic halogen compounds.The amount of the antiseptic can be suitably selected, and is, forexample, up to about 4 percent by weight based on the total weight (assolids content) of the composition.

Examples of the biocides, which are used either as wet-state protectorsor as film protectors of a coating composition, are a wide variety ofbactericides, fungicides or algicides, and include, but are not limitedto, zinc oxide, cuprous oxide, organotin pigments, copolymers oforganotin esters of methacrylic acid with acrylates, tributyl tin oxide,and mixtures thereof. Other examples of biocides particularly useful aswet-state protectors are oxazoladines, organosulfurs, andbenzisothiazolins. Any general toxic agent may be suitable as a biocide.

The dispersing agents include, but are not limited to, sodium salts ofpolycarboxylic acids, sodium or ammonium salts of fused naphthalenesulfonate, polyoxyalkylene alkyl ethers of phenol ether, sorbitan fattyacid esters, polyoxyalkylene fatty acid esters, glycerin fatty acidesters, polyoxyethylene styrene phenol, sodium tripolyphosphate andsodium hexametaphosphate. As described above, organosilanol derivativesof tung oil, or linseed oil, or high erucic acid rapeseed oil that areuseful as surfactants are also suitable as dispersing agents. The amountof the dispersing agent generally ranges up to about 10 weight percentbased on the total weight of the composition.

The thickening and thixotropic agents may be one and the same ordifferent and may be the same as the protective colloids referred toabove. Examples of thickening or thixotropic agents are polyvinylalcohol, cellulose derivatives such as hydroxyethyl cellulose,hydroxypropyl cellulose and carboxymethyl cellulose salt, polyethercompounds, urethane modified polyether compounds, polycarboxylic acidcompounds, sodium salts of polycarboxylic compounds,polyvinylpyrrolidone, polyoxyethylene derivatives such as polyethyleneglycol ether and polyethylene glycol distearate, sodium alginate andinorganic materials such as sodium silicate and bentonite. The amountsof the thickening or the thixotropic agents can be properly chosendepending upon the type of end-application of the composition of thepresent invention.

Examples of the pH adjusting agents include, but are not limited to,sodium hydroxide, potassium hydroxide, sodium hydrogen carbonate,ammonium hydroxide, ammonia, amines, triethanolamine, and3-dimethylaminoethanol. The amount of the pH adjusting agent is selectedsuch that the composition has a desired pH.

Examples of the crosslinking promoters include, but are not limited to,carbodiimides.

Uses of the compositions of the present invention include, but are notlimited to, coatings, including original equipment manufacture (OEM)automotive coatings, refinish automotive coatings, architecturalcoatings, paper coatings, textile coatings, industrial coatings,furniture coatings, powder coatings, graphic arts, inks, adhesives,binders, nonwovens, paper saturation, medical applications (such asdentifrice, sutures, and bandages), and construction chemicals.

One or more crosslinking agents or crosslinkers can be added to thepolymer composition of the present invention when it is used alone, in acoatings formulation or in a blend with other polymer compositions.Polymer crosslinking provides chemical and stain resistance in coatingsas well improved processability, toughness, and service life in otherapplications. All the chemical compounds known to crosslink with theacetoacetate moiety can be used to effect the crosslinking reaction.Examples of the crosslinking agents include, but not limited to,melamines, isocyanates, electron-deficient olefins, diamines,polyaldehydes. An overview of the various crosslinking possibilities ofthe acetoacetate moiety is given by Stacey J. Marsh and published in“The Acetoacetate Functionality”, Proceedings of short course onCrosslinking for the Coatings Chemist, 2002 FSCT International CoatingsTechnology Conference.

When the polymer composition of the present invention is used alone, ina coatings formulation, or in a blend with other polymer compositions,it can be further crosslinked or cured by at least one of autooxidationand actinic radiation. When cured by actinic radiation, an actinicradiation curing agent can be included. Examples of actinic radiationcuring agents include, but are not limited to, benzophenone,4-methylbenzophenone, benzoyl benzoates, phenylacetophenones,2,2-dimethoxy-2-phenylacetophenone, and amine modified diacrylates. Theamount of actinic radiation curing agents that can be included in thecompositions can be any amount that promotes or accelerates curing orhardening of the polymers. Generally, the amount of actinic radiationcuring agents ranges from about 0% to about 1% based on the weight ofthe composition, and preferably from about 0% to about 0.5%.

Specific Embodiments of the Invention

The invention is further described in the following examples. Theexamples are merely illustrative and do not in any way limit the scopeof the invention as described and claimed.

The viscosities of the polymer dispersions were measured throughoutusing a Brookfield Viscometer (Model RVDV-II+) with either spindle #2 ata speed of 50 rpm for viscosities below about 800 cps or spindle #3 at aspeed of 50 rpm for viscosities higher than about 800 cps.

The preferred emulsion polymerization process is a semi-continuous onein which all or the bulk of the monomers are added over a period of timeinto the reactor during polymerization. A semi-continuous process mayinclude semi-batch with starved or non-starved monomer feeding, gradientfeeding, power feeding, one-stage, multi-stage, swelling polymerizationetc. A seed can be used for better control of particle size and/orparticle size distribution.

An amount of a 5% solution of ammonium persulfate initiator was preparedfresh and placed in a feeding vessel. Initiator was added to thepolymerization reactor via a feed tube having a valve to control thefeed rate.

To a stirred pre-emulsion vessel were added specified amounts ofdeionized (DI) water, seed, surfactants, etc. This mixture was agitatedto create an emulsion. Additional monomer emulsions or monomer mixtureswere optionally prepared in separate vessels and transferred to thepre-emulsion vessel as outlined in the accompanying description. Thepre-emulsion vessel was connected to the polymerization reaction via afeeding line with a valve to control the rate of feed.

Feeding rates of monomer emulsion and initiator were computer-controlledso that exact amounts were delivered into the polymerization reactor.The temperature of the reactor was controlled by a thermostated waterbath. Reactor contents were agitated at a sufficient speed so as toprovide adequate mixing of reaction components. All reaction conditionsare given in the tables below.

Abbreviations

-   MMA: methyl methacrylate-   BA: n-butyl acrylate-   AAEMA: 2-acetoacetoxyethyl methacrylate (from Eastman Chemical)-   MAA: methacrylic acid-   AA: acrylic acid-   IA: itaconic acid

COMPARATIVE EXAMPLE 1 (CE1)

MMA/BA/AAEMA Copolymer Dispersion Without the Use of a Base DuringPolymerization

A polymerization reactor was charged with 407.9 g of water, 10.0 g ofPLURIOL® A010R monomer (BASF Corporation) and 47.1 g of a polystyreneseed latex (32.2% by weight; average particle diameter d₅₀=30 nm) andthis initial charge was heated to 85° C. Then 3.0 g of a 5.0% strengthby weight aqueous solution of ammonium persulfate were added in oneportion into the reactor. Commencing simultaneously, the remaininginitiator solution was added to the polymerization reactor over thecourse of 192 minutes and the Monomer Emulsion I was added over 144minutes. The temperature was maintained at 85° C. After the end of theaddition of Monomer Emulsion I, the continuous feed of Monomer EmulsionII was started immediately and lasted 24 minutes. After the end of theaddition of Monomer Emulsion II, the reactor was maintained at 85° C.for 30 more minutes and then cooled down to 75° C. 6.43 g of a 28%strength by weight aqueous ammonia and 55 g of water were added. Tofurther reduce the amount of residual monomers, the following chemicalstripping process was applied: 21.67 g of a 4.62% strength by weightaqueous solution of t-butyl hydroperoxide and 21.67 g of a 6% strengthby weight aqueous solution of sodium acetone bisulfite were fedseparately and continuously into the reactor over 30 minutes. Thereactor was maintained at 75° C. for 30 more minutes and then cooleddown to room temperature. 20.36 g of a 28% strength by weight aqueousammonia and 6.67 g of a 1.5% strength by weight aqueous solution of abiocide were added. The polymer dispersion was essentially free ofcoagulum, had a pH of 9.34, solids content of 49.96% by weight and aBrookfield viscosity of 2540 cps. The pH values during emulsionpolymerizations were recorded. Table 1 summarizes pH values measured,final latex viscosity, and paint scrub resistance. The compositions ofthe monomer emulsions were as follows: Monomer Emulsion I 250.38 g water 33.33 g emulsifier 1¹  15.63 g emulsifier 2²  13.16 g emulsifier 3³ 10.00 g MAA  12.50 g IA  25.00 g 50% strength by weight aqueoussolution of acrylamide  0.00 g 10% strength by weight aqueous solutionof sodium hydroxide  40.00 g AAEMA 540.00 g BA 275.00 g MMA

Monomer Emulsion II 111.67 g of water  33.33 g of emulsifier 1¹  1.00 gof tert-dodecyl mercaptan  99.00 g of MMA

-   -   ¹Emulsifier 1: A 15% strength aqueous solution of sodium lauryl        sulfate under the trade name of TEXAPON™ K12-15 from Cognis        Corporation    -   ²Emulsifier 2: A 33% strength aqueous solution of sodium lauryl        ether sulfate, 30-EO moles under the trade name of DISPONIL™ FES        77 IS from Cognis Corporation    -   ³Emulsifier 3: A 38% strength aqueous slurry of sodium aryl        sulfonate, under the trade name of CALSOFT™ L-40S from Pilot        Chemical Company

EXAMPLE 1 (E1)

MMA/BA/AAEMA Copolymer Dispersion Prepared by Using a Base DuringPolymerization

The polymerization recipe and process is similar to that of CE1, exceptNaOH was added into the Monomer Emulsion I. The compositions of EmulsionI and II are given below. After the emulsion polymerization and thechemical stripping processes, the polymer dispersion has been cooleddown to room temperature, 17.32 g of a 28% strength by weight aqueousammonia and the same amount of the biocide as in CE1 were added. Theproduct was essentially free of coagulum, had a pH of 9.2, solidscontent of 50.10% by weight and a Brookfield viscosity of 690 cps. ThepH values during emulsion polymerizations were recorded. Table 1summarizes pH values measured, final latex viscosity, and paint scrubresistance. The compositions of the monomer emulsions were as follows:Monomer Emulsion I 242.73 g water  33.33 g emulsifier 1  15.63 gemulsifier 2  13.16 g emulsifier 3  10.00 g MAA  12.50 g IA  25.00 g a50% strength by weight aqueous solution of acrylamide  8.50 g a 10%strength by weight aqueous solution of sodium hydroxide  40.00 g AAEMA540.00 g BA 270.00 g MMA

Monomer Emulsion II 111.67 g water  33.33 g emulsifier 1  1.00 gtert-dodecyl mercaptan  99.00 g MMA

EXAMPLE 2 (E2)

MMA/BA/AAEMA Copolymer Dispersion Prepared by Using a Base duringPolymerization

The polymerization recipe and process is similar to that of CE1, exceptNaOH was added into the Monomer Emulsion I. The compositions of EmulsionI and II are given below. After the emulsion polymerization and thechemical stripping processes, the polymer dispersion was cooled down toroom temperature, 14.29 g of a 28% strength by weight aqueous ammoniaand the same amount of the biocide as in CE1 were added. The product wasessentially free of coagulum, had a pH of 9.29, solids content of 49.48%by weight and a Brookfield viscosity of 320 cps. The pH values duringemulsion polymerizations were recorded. Table 1 summarizes pH valuesmeasured, final latex viscosity, and paint scrub resistance. Thecompositions of the monomer emulsions were as follows: Monomer EmulsionI 235.08 g water  33.33 g emulsifier 1  15.63 g emulsifier 2  13.16 gemulsifier 3  10.00 g MAA  12.50 g IA  25.00 g 50% strength by weightaqueous solution of acrylamide  17.00 g 10% strength by weight aqueoussolution of sodium hydroxide  40.00 g AAEMA 540.00 g BA 275.00 g MMA

Monomer Emulsion II 111.67 g water  33.33 g emulsifier 1  1.00 gtert-dodecyl mercaptan  99.00 g MMA

Paint Formulation and Evaluation:

The dispersions of Comparative Example CE1 and Examples E1 and E2 wereall formulated into semi-gloss paints using the same formulation as inthe following: Ingredient Parts (g) Semi Gloss Paint Formulation (withabout 50 g/L VOC): Water 65.9 Ethylene glycol 13.0 NATROSOL ™ 330 Plus¹⁾1.0 AMP ™-95²⁾ 2.0 Pigment dispersant³⁾ 10.0 Biocide⁴⁾ 3.0 Defoamer⁵⁾2.0 Extender A⁶⁾ 50.0 Extender B⁷⁾ 25.0 Thickner⁸⁾ 24.0 Titanium DioxideSlurry⁹⁾ 294.0 Ground for 20 min. at 1000 RPM and then added thefollowing constituents: Coalescent¹⁰⁾ 2.0 Defoamer⁵⁾ 1.5 PolymerDispersion (50%) 517.7 Water 61.6¹⁾NATROSOL ™ 330 Plus thickener from Hercules Inc.²⁾AMP-95: Angus Chemical Comapany³⁾TAMOL ™ 731 dispersant from Rohm & Haas Comapany⁴⁾PROXEL ™ BD 20 biocide from Avecia Inc.⁵⁾DREWPLUS ™ L-475 defoamer from Ashland Speccialty Chemical⁶⁾BURGESS ™ 28 filler from Burgess Pigment⁷⁾MINEX ™ 7 filler from Unimin Specialty Minerals Corporation⁸⁾AQUAFLOW ™ NHS 310 flow control aid from Hercules Inc.⁹⁾TI-PURE ™ R 746 titanium dioxide pigment from E.I. DuPont de Nemours¹⁰⁾TEXANOL ™ solvent from Eastman Chemical Company

The low-shear viscosities of the paints ranged from 100 to 117 K.U.(Krebs Units), whereas the high-shear viscosities ranged from 1.5 to 1.7poises (measured according to ASTM D4287 and D562-81, respectively).

The scrub resistance of the paints was tested according to ASTM D-2486using a “Gardner” scrub machine and the standardized scrub medium SC-2.The paints were applied with the help of a film applicator to the Lenetascrub panels with a wet thickness of about 175 μm. The draw-down filmswere dried in a climate-controlled room (50% Relative Humidity and 23°C.) for 7 days before the scrub test. TABLE 1 pH during Polymerizationat different times* Final Latex Scrub Neutralizing 0 15 30 60 120Viscosity Resistance Agent min. min. min. min. min. (cps) (cycles) CE1No NaOH 3.46 2.95 2.90 2.94 3.14 2540 1220 addition duringpolymerization E1 0.085%** 3.61 3.56 3.63 3.79 3.91 690 2335 NaOH addedduring polymerization in Monomer Emulsion 1 E2 0.170%** 3.62 3.58 3.613.78 3.91 320 2950 NaOH added during polymerization in Monomer Emulsion1*Time from the start of monomer emulsion feed in which different amountof NaOH was added. pH at 0 minute was the value before the start ofemulsion feed;**weight % of NaOH based on total weight of polymer.

The results in Table 1 indicate that: Examples E1 and E2 had higher pHvalues after the start of the monomer emulsion feeds (at time >0 minute)due to the use of NaOH during polymerization. The use of the base sodiumhydroxide in monomer emulsion during emulsion polymerization resulted insignificantly lower latex viscosity (CE1 vs. E1 and E2). Reduced latexviscosity is desirable for ease of manufacturing and transportation. Theuse of the base sodium hydroxide in monomer emulsion during emulsionpolymerization resulted in significantly higher scrub resistance (CE1vs. E1 and E2). High scrub resistance is a desirable property of latexpaint.

COMPARATIVE EXAMPLE 2 (CE2)

MMA/BA/AAEMA Copolymer Dispersion Without the Use of a Base DuringPolymerization

A polymerization reactor was charged with 407.9 g of water, 15.0 g ofPLURIOL® A010R monomer (BASF Corporation) and 47.1 g of a polystyreneseed latex (32.2% by weight; average particle diameter d₅₀=30 nm) andthis initial charge was heated to 85° C. Then 3.0 g of a 5.0% strengthby weight aqueous solution of ammonium persulfate were added in oneportion. Commencing simultaneously, the remaining initiator solution wasadded to the polymerization reactor over the course of 192 minutes andthe Monomer Emulsion I was added over 144 minutes. The temperature wasmaintained at 85° C. After the end of the addition of Monomer EmulsionI, the continuous feed of Monomer Emulsion II was started immediatelyand lasted 24 minutes. After the end of the addition of Monomer EmulsionII, the reactor was maintained at 85° C. for 30 more minutes and thencooled down to 75° C. 6.43 g of a 28% strength by weight aqueous ammoniaand 55 g of water were added. To further reduce the amount of residualmonomers, the following chemical stripping process was applied: 21.67 gof a 4.62% strength by weight aqueous solution of t-butyl hydroperoxideand 21.67 g of a 6% strength by weight aqueous solution of sodiumacetone bisulfite were fed separately and continuously into the reactorover 30 minutes. The reactor was maintained at 75° C. for 30 moreminutes and then cooled down to room temperature. 20.36 g of a 28%strength by weight aqueous ammonia and 6.67 g of a 1.5% strength byweight aqueous solution of a biocide were added. The polymer dispersionwas essentially free of coagulum, had a pH of 9.40, solids content of49.78% by weight, and a Brookfield viscosity of 3030 cps. Some wetproperties of the polymer dispersion and the scrub resistance of thesemi-gloss paint based on the polymer dispersion are summarized in Table2. The compositions of the monomer emulsions were as follows: MonomerEmulsion I 250.38 g water  33.33 g emulsifier 1¹  15.63 g emulsifier 2² 13.16 g emulsifier 3³  10.00 g MAA  12.50 g IA  25.00 g 50% strength byweight aqueous solution of acrylamide  0.00 g 10% strength by weightaqueous solution of sodium hydroxide  40.00 g AAEMA 540.00 g BA 270.00 gMMA

Monomer Emulsion II 111.67 g of water  33.33 g of emulsifier 1¹  1.00 gof tert-dodecyl mercaptan  99.00 g of MMA

EXAMPLE 3 (E3)

MMA/BA/AAEMA Copolymer Dispersion Prepared by Using a Base DuringPolymerization

The polymerization recipe and process is similar to that of CE2, exceptNaOH was added into the Monomer Emulsion I. The compositions of EmulsionI and II are given below. After the emulsion polymerization and thechemical stripping processes, the polymer dispersion was cooled down toroom temperature, 17.32 g of a 28% strength by weight aqueous ammoniaand the same amount of the biocide as in CE2 were added. The product wasessentially free of coagulum, had a pH of 9.33, solids content of 49.56%by weight, and a Brookfield viscosity of 980 cps. Some wet properties ofthe polymer dispersion and the scrub resistance of the semi-gloss paintbased on the polymer dispersion are summarized in Table 2. Thecompositions of the monomer emulsions were as follows: Monomer EmulsionI 242.73 g water  33.33 g emulsifier 1  15.63 g emulsifier 2  13.16 gemulsifier 3  10.00 g MAA  12.50 g IA  25.00 g 50% strength by weightaqueous solution of acrylamide  8.50 g 10% strength by weight aqueoussolution of sodium hydroxide  40.00 g AAEMA 540.00 g BA 270.00 g MMA

Monomer Emulsion II 111.67 g water  33.33 g emulsifier 1  1.00 gtert-dodecyl mercaptan  99.00 g MMA

COMPARATIVE EXAMPLE 3 (CE3)

MMA/BA/AAEMA Copolymer Dispersion Without the Use of a Base DuringPolymerization

The polymerization recipe and process is similar to that of E3, exceptno NaOH was added into the Monomer Emulsion I. Instead, the 8.50 g of a10% aqueous solution of sodium hydroxide was added into the latex afterthe chemical stripping and cooling down steps. The final product wasessentially free of coagulum, had a pH of 9.05, solids content of 49.53%by weight, and a Brookfield viscosity of 2420 cps. Some wet propertiesof the polymer dispersion are summarized in Table 2.

EXAMPLE 4 (E4)

MMA/BA/AAEMA Copolymer Dispersion Prepared by Using a Base DuringPolymerization

The polymerization recipe and process is similar to that of CE2, exceptNaOH was added into the Monomer Emulsion I. The compositions of EmulsionI and II are given below. After the emulsion polymerization and thechemical stripping processes, the polymer dispersion was cooled down toroom temperature, 14.29 g of a 28% strength by weight aqueous ammoniaand the same amount of the biocide as in CE2 were added. The product wasessentially free of coagulum, had a pH of 9.20, solids content of 49.70%by weight, and a Brookfield viscosity of 390 cps. Some wet properties ofthe polymer dispersion and the scrub resistance of the semi-gloss paintbased on the polymer dispersion are summarized in Table 2. Thecompositions of the monomer emulsions were as follows: Monomer EmulsionI 235.08 g water  33.33 g emulsifier 1  15.63 g emulsifier 2  13.16 gemulsifier 3  10.00 g MAA  12.50 g IA  25.00 g 50% strength by weightaqueous solution of acrylamide  17.00 g 10% strength by weight aqueoussolution of sodium hydroxide  40.00 g AAEMA 540.00 g BA 270.00 g MMA

Monomer Emulsion II 111.67 g water  33.33 g emulsifier 1  1.00 gtert-dodecyl mercaptan  99.00 g MMA

COMPARATIVE EXAMPLE 4 (CE4)

MMA/BA/AAEMA Copolymer Dispersion Without the Use of a Base DuringPolymerization

The polymerization recipe and process is similar to that of E4, exceptno NaOH was added into the Monomer Emulsion I. Instead, the 17.0 g of a10% aqueous solution of sodium hydroxide was added into the latex afterthe chemical stripping and cooling down steps. The final product wasessentially free of coagulum, had a pH of 8.97, solids content of 49.63%by weight, and a Brookfield viscosity of 2188 cps. Some wet propertiesof the polymer dispersion are summarized in Table 2.

Paint Formulation and Evaluation

The dispersions of Comparative Examples CE2 through CE4, and Examples E3and E4 were all formulated into semi-gloss paints using the sameformulation as shown above. The low-shear viscosities of the paintsranged from 95 to 117 K.U. (Krebs Units), whereas the high-shearviscosities ranged from 1.35 to 1.68 poises (measured according to ASTMD 4287 and D 562-81, respectively). The draw-down films were prepared asdescribed above and scrub test was performed according to ASTM D-2486.TABLE 2 Latex Latex Vis- Scrub Solids cosity Resistance NeutralizingAgent NaOH (%) (cps) (cycles) Comparative No NaOH addition during 49.83030 1500 Example 2 polymerization (CE2) Example 3 0.085%* NaOH added49.6 980 2330 (E3) during polymerization in Monomer Emulsion 1Comparative 0.085%* NaOH added after 49.5 2420 Not tested Example 3 theend of polymerization (CE3) Example 4 0.170%* NaOH added 49.7 390 2660(E4) during polymerization in Monomer Emulsion 1 Comparative 0.170%*NaOH added after 49.6 2190 Not tested Example 4 the end ofpolymerization (CE4)*weight % of NaOH based on total weight of copolymer.

The results in Table 2 indicate that the use of the base sodiumhydroxide in monomer emulsion results in significantly lower latexviscosity than the case where no NaOH is used during emulsionpolymerization (CE2 vs. E3 and E4). The viscosity of the latex issignificantly lower when the base sodium hydroxide is used in emulsionfeed during polymerization than when it is used after the polymerization(E3 vs. CE3, and E4 vs. CE4). The use of the base sodium hydroxide inmonomer emulsion during emulsion polymerization results in significantlyhigher scrub resistance (CE2 vs. E3 and E4).

EXAMPLE 5 (E5)

MMA/BA/AAEMA Copolymer Dispersion Prepared by Using Ammonium HydroxideDuring Polymerization

The polymerization recipe and process is similar to that of CE1, exceptammonium hydroxide was added into the Monomer Emulsion I. Thecompositions of Emulsion I and II are given below. After the emulsionpolymerization and the chemical stripping processes, the polymerdispersion was cooled down to room temperature, 14.29 g of a 28%strength by weight aqueous ammonia and the same amount of the biocide asin CE1 were added. The product was essentially free of coagulum, had apH of 9.24, solids content of 49.89% by weight, and a Brookfieldviscosity of 160 cps. Table 3 summarizes some properties of the wetlatex the the semi-gloss paint based on this latex. The compositions ofthe monomer emulsions were as follows: Monomer Emulsion I 246.01 g water 33.33 g emulsifier 1  15.63 g emulsifier 2  13.16 g emulsifier 3  10.00g MAA  12.50 g IA  25.00 g 50% strength by weight aqueous solution ofacrylamide  6.07 g 28% strength by weight aqueous solution of ammoniumhydroxide  40.00 g AAEMA 540.00 g BA 270.00 g MMA

Monomer Emulsion II 111.67 g water  33.33 g emulsifier 1  1.00 gtert-dodecyl mercaptan  99.00 g MMA

EXAMPLE 6 (E6)

MMA/BA/AAEMA Copolymer Dispersion Prepared by Using Amp(2-Amino-2-Methyl-1-Propanol) During Polymerization

The polymerization recipe and process is similar to that of CE1, except2-amino-2-methyl-1-propanol was added into the Monomer Emulsion I. Thecompositions of Emulsion I and II are given below. After the emulsionpolymerization and the chemical stripping processes, the polymerdispersion was cooled down to room temperature, 14.29 g of a 28%strength by weight aqueous ammonia and the same amount of the biocide asin CE1 were added. The product was essentially free of coagulum, had apH of 8.94, solids content of 50.35% by weight, and a Brookfieldviscosity of 930 cps. Table 3 summarizes some properties of the wetlatex the the semi-gloss paint based on this latex. The compositions ofthe monomer emulsions were as follows: Monomer Emulsion I 250.29 g water 33.33 g emulsifier 1  15.63 g emulsifier 2  13.16 g emulsifier 3  10.00g MAA  12.50 g IA  25.00 g 50% strength by weight aqueous solution ofacrylamide  1.79 g 95% strength by weight aqueous solution of 2-amino-2-methyl-1-propanol  40.00 g AAEMA 540.00 g BA 275.00 g MMA

Monomer Emulsion II 111.67 g water  33.33 g emulsifier 1  1.00 gtert-dodecyl mercaptan  99.00 g MMA

EXAMPLE 7 (E7)

MMA/BA/AAEMA Copolymer Dispersion Prepared by Using Potassium HydroxideDuring Polymerization

The polymerization recipe and process is similar to that of CE1, exceptKOH was added into the Monomer Emulsion I. The compositions of EmulsionI and II are given below. After the emulsion polymerization and thechemical stripping processes, the polymer dispersion was cooled down toroom temperature, 14.29 g of a 28% strength by weight aqueous ammoniaand the same amount of the biocide as in CE1 were added. The product wasessentially free of coagulum, had a pH of 8.93, solids content of 50.23%by weight, and a Brookfield viscosity of 1550 cps. Table 3 summarizessome properties of the wet latex the the semi-gloss paint based on thislatex. The compositions of the monomer emulsions were as follows:Monomer Emulsion I 235.08 g water  33.33 g emulsifier 1  15.63 gemulsifier 2  13.16 g emulsifier 3  10.00 g MAA  12.50 g IA  25.00 g 50%strength by weight aqueous solution of acrylamide  17.00 g 10% strengthby weight aqueous solution of potassium hydroxide  40.00 g AAEMA 540.00g BA 275.00 g MMA

Monomer Emulsion II 111.67 g water  33.33 g emulsifier 1  1.00 gtert-dodecyl mercaptan  99.00 g MMA

Paint Formulation and Evaluation

The dispersions of Comparative Examples CE1 and Examples E5 and E7 wereall formulated into semi-gloss paints using the same formulation asshown above. The low-shear viscosities of the paints ranged from 93 to121 K.U. (Krebs Units), whereas the high-shear viscosities ranged from1.2 to 1.7 poises (measured according to ASTM D 4287 and D 562-81,respectively). The draw-down films were prepared as described above andscrub test was performed according to ASTM D-2486. TABLE 3 Latex LatexScrub Neutralizing Solids Viscosity Resistance Agent NaOH (%) (cps)(cycles) Comparative No addition of a base 49.8 2540 1220 Example 1during polymerization (CE1) Example 5 0.170%* NH₄OH added 49.9 160 3540(E5) during polymerization in Monomer Emulsion 1 Example 6 0.170%* AMP(2-amino- 50.4 930 1880 (E6) 2-methyl-1-propanol) added duringpolymeriza- tion in Monomer Emulsion 1 Example 7 0.170%* KOH added (E7)during polymerization in 50.2 1550 1610 Monomer Emulsion 1*weight % of the base used based on total weight of copolymer.

The results in Table 3 indicate that in addition to sodium hydroxide,other bases, such as ammonium hydroxide, AMP, and potassium hydroxide,also reduce latex viscosity when used in monomer emulsion feeds duringpolymerization (CE1 vs. E5 through E7). Similarly to sodium hydroxide,ammonium hydroxide, AMP, and potassium hydroxide also improve scrubresistance of paint when used in monomer emulsion feeds duringpolymerization (CE2 vs. E5 through E7).

It should be appreciated that the present invention is not limited tothe specific embodiments described above, but includes variations,modifications and equivalent embodiments defined by the followingclaims.

1. A method of making a composition comprising reacting, in a reactor,a. a non-halogenated acetoacetate group containing monomer, b. at leastone additional monomer, and c. a base, wherein at least a portion of thebase is fed to the reactor during reaction and wherein the base is addedduring the reacting step in an amount such that the pH is not higherthan
 7. 2. The method of claim 1, wherein one of: a. none of the base ispresent in the reactor at the start of the reacting step and the base ismixed with the monomers and is added during the reacting step, b. noneof the base is present in the reactor at the start of the reacting stepand the base is fed into the reactor separately from the monomers duringthe reacting step, c. none of the base is present in the reactor at thestart of the reacting step and the base is fed into the reactor mixedwith the monomers and separately from the monomers during the reactingstep, d. less than 50% of the base is present in the reactor at thestart of the reacting step and the remainder of the base is mixed withthe monomers and is added during the reacting step, e. less than 50% ofthe base is present in the reactor at the start of the reacting step andthe remainder of the base is fed into the reactor separately from themonomers during the reacting step, or f. less than 50% of the base ispresent in the reactor at the start of the reacting step and theremainder of the base is fed into the reactor nixed with the monomersand separately from the monomers during the reacting step.
 3. The methodof claim 1, wherein the base is at least one of an alkali metalhydroxide, an alkaline earth metal hydroxide, lithium hydroxide, sodiumhydroxide, potassium hydroxide, calcium hydroxide, magnesium hydroxide,barium hydroxide, ammonia, ammonium hydroxide, an amine, methylamine,ethylamine, propylamine, dimethylamine, diethylamine, trimethylamine,triethylamine, 2-amino-2-methyl-1-propanol, and triethanolamine.
 4. Themethod of claim 1, wherein the base is at least one of a compound withbuffering capability, an alkali metal carbonate, an alkali metalbicarbonate, ammonium carbonate, ammonium bicarbonate, a monobasicphosphate, an ammonium dibasic phosphate, a tetroxalate of an alkalimetal, a tartrate of an alkali metal, ammonium tetroxalate, ammoniumtartrate, a phthalate of an alkali metal, and ammonium phthalate.
 5. Themethod of claim 1, wherein the base is added during the reacting step inan amount to provide a pH that is at least 0.2 units higher than wouldbe obtained if the base were not present.
 6. (canceled)
 7. The method ofclaim 1, wherein the base is added during the reacting step in an amountto provide a pH that is at least 0.2 units higher than would be obtainedif the base were not present.
 8. The method of claim 1, wherein the baseis used in an amount of from about 0.01 to about 2 weight % based on atotal weight of the polymer.
 9. The method of claim 1 further comprisingreacting a functional monomer with the other monomers to form thepolymer, wherein the at least one additional monomer is not a functionalmonomer, and wherein the functional monomer is a monomer that has atleast one of a functional group in addition to a carbon-carbon doublebond or has at least two sites of ethylenic unsaturation.
 10. The methodof claim 9, wherein the functional monomer is present in an amount fromabout 0.05 to about 5 weight % based on a total weight of the polymer.11. The method of claim 9, wherein the functional monomer is at leastone of a mono-ethylenically unsaturated acid, a mono-ethylenicallyunsaturated diacid, (meth)acrylic acid, itaconic acid, maleic acid, anitrogen-containing monomer, (meth)acrylamide, ureido (meth)acrylate,ureido (meth)acrylamide, acrylamidomethylpropylsulfonic acid, a salt ofacrylamidomethylpropylsulfonic acid, a silane monomer,methacryloxypropyl trimethoxysilane, methacryloxypropyl triethoxysilane,methacryloxypropyl tripropoxysilane, methacryloxypropyltriisopropoxysilane, vinyltrimethoxysilane, vinyltriethyoxysilane, amonomer with at least two sites of ethylenic unsaturation, ethyleneglycol dimethacrylate, diethylene glycol dimethacrylate,trimethylolpropane trimethacrylate, 1,3-butyleneglycol dimethacrylate,1,4-butyleneglycol dimethacrylate, an ethoxylated vinyl monomer, anethoxylated (meth)acrylic monomer,


12. The method of claim 1, wherein the non-halogenated acetoacetatemoiety containing monomer is present in an amount from about 0.1 toabout 25 weight % based on a total weight of the polymer.
 13. The methodof claim 1, wherein the non-halogenated acetoacetate moiety containingmonomer is at least one of 2-acetoacetoxyethyl (meth)acrylate,2-cyanoacetoxyethyl (meth)acrylate, N-(2-acetoacetoxyethyl)(meth)acrylamide, 3-acetoacetoxypropyl (meth)acrylate,4-acetoacetoxybutyl (meth)acrylate, 3-cyanoacetoxypopyl (meth)acrylate,4-cyanoacetoxybutyl (meth)acrylate, allyl acetoacetate,2,3-di(acetoacetoxy)propyl (meth)acrylate, and vinyl acetoacetate. 14.The method of claim 1, wherein the at least one additional monomer ispresent in an amount from about 70 to about 99.9 weight % based on atotal weight of the polymer. 15-28. (canceled)